Method and Apparatus for Providing an Insulated Shipping Container

ABSTRACT

Disclosed is an insulated shipping container for transporting temperature-controlled materials and method of making the same. In a preferred embodiment, the insulated shipping container comprises an outer box or housing and a plurality of insulated inserts configured to be snugly and removably received in the outer box or housing. The plurality of insulated inserts are shaped to define a rectangular cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps. The insulated inserts as well the outer box or housing of the disclosed device can be stored flat and reused.

FIELD OF ART

The disclosed device relates generally to an insulated shipping container for use in shipping temperature sensitive products or to help maintain product freshness and efficacy, and more particularly to insulated shipping containers of the type which are formed at least in part of foamed polymer material.

BACKGROUND

Conventional insulated shipping containers known as a box-within-a-box are well-known. These conventional box-within-a-box containers typically have an outer box formed of corrugated cardboard and a smaller, open-topped, inner box also formed of corrugated cardboard, the outer and inner boxes defining a void space therebetween. During manufacture of such shipping containers, the void space is filled with a foamed-in-place polymer material, said polymer material typically being a light-to-medium density foamed polyurethane material. The polymer material in a liquid pre-foamed condition is then sprayed or poured into the void space between the two boxes and is allowed to foam in place. The foaming of the polymer material takes a sufficient period of time and as this polymer material foams in place, it bonds to both the inner and outer boxes and exerts a considerable pressure against both the inner and outer boxes.

With such conventional insulated shipping containers, it is common for one or more articles being shipped therein to be inserted into the inner box of the container, together with dry ice or other temperature stabilizing packs and packing material. A form-fitting block of thick, open-cell foam is then inserted into the opening of the inner box. This open-cell foam serves as a thermal insulator and prevents the infusion of ambient air into the inner box and the escape of temperature-controlled air from within the inner box. Next, the top closure flaps of the outer box are closed and taped, and the shipping container is ready for shipment with the attachment of a shipping label thereto.

Unfortunately, conventional box-within-a-box containers have certain shortcomings. One significant shortcoming is that the materials of the container are not recyclable because the foamed polymer material bonds directly to the inner and outer cardboard boxes and cannot thereafter easily be separated therefrom. Moreover, if the outer box becomes damaged or otherwise marked, it cannot be replaced in such a way as to permit the container to be reused.

Common also in the industry for shipping perishable items is a molded polystyrene cooler. While this is currently the most economical and efficient product available, there are several shortcomings with this product. First, these coolers require an expensive mold to be produced. Next, each cooler has a particular size and wall thickness, which results in a shipper having to purchase and keep in stock a variety of cooler sizes. In addition, these coolers ship pre-molded, so they take up a lot of space.

The disclosed device provides for an improved and inexpensive thermal packaging product comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides. The disclosed device is configured to be compact and accommodates flat storage. If the outer box becomes damaged or otherwise marked, the insulated inserts can easily be placed into another outer box or housing, thereby allowing for reuse. In addition, each cooler can be composed of inserts of customizable sizes and wall thicknesses.

SUMMARY OF THE DISCLOSURE

The disclosed device provides for an improved thermal packaging product comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides.

The disclosed device comprises scoring of an internally-based sheet of polystyrene before it is inserted into or encapsulated by a metallized polyethylene material, the scoring allowing the polystyrene sheet to bend or crack at a predetermined spot to reduce the likelihood of voids in packaging.

The disclosed device provides for a thermal packaging product that utilizes a metallized polyethylene material such as “bubble foil”.

The disclosed device provides for a thermal packaging product that utilizes a metallized polyethylene material with reflective properties that reflect radiant heat.

The disclosed device provides for a thermal packaging product that adds two (2) layers of additional material to a polystyrene base, thereby further limiting heat transfer through conduction.

The disclosed device provides for a thermal packaging product that may be reused.

The disclosed device provides for a thermal packaging product that does not readily absorb odors or fluids.

The disclosed device provides for a thermal packaging product that can be easily cleaned and/or disinfected for reuse.

The disclosed device allows for a user to determine the appropriate amount of insulation thickness to be used without having to be confined to using a pre molded container that consists of too little or too much insulation.

The disclosed device can be manufactured to a shipper's size requirements.

The disclosed device can be manufactured to accommodate flat storage.

The disclosed device can be stored in a flat configuration until it is folded into a usable expanded unit, .i.e., a 3-dimensional unit.

The disclosed device does not require the use of expensive molds for manufacturing purposes, thus reducing potential equipment set-up and capital costs.

The disclosed device can be made into large to very large sizes, unlike pre-molded coolers.

The disclosed device provides for a thermal packaging product that even if cracked internally, the metallized polyethylene material acts as an encapsulating seal to maintain the efficiency of the product.

The disclosed device provides for an improved thermal packaging product that outperforms a comparable molded cooler by about twenty percent (20%).

The disclosed device allows for a thermal packaging product having a desired insulation thickness in the range of about 0.5″ to about 4″.

The disclosed device is compact.

The disclosed device provides for an insulated shipping container for transporting temperature-controlled materials which can include cold and hot temperature items.

These and other advantages of the disclosed device will appear from the following description and/or appended claims, reference being made to the accompanying drawings that form a part of this specification wherein like reference characters designate corresponding parts in the several views.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts various embodiments 100, 200 of the disclosed thermal packaging product comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides.

FIG. 2 illustrates the ability of the disclosed thermal packaging product to accommodate flat shipping and storage.

FIG. 3 illustrates the bendability of the disclosed device and the ease by which the device can be folded into a 3 dimensional unit.

FIG. 4 depicts a standard corrugated cardboard box 300 into which the disclosed device may be inserted.

FIG. 5 illustrates the insertion of thermal packaging product 100 into standard corrugated cardboard box 300.

FIG. 6 illustrates the insertion of thermal packaging product 200 into cardboard box 300 which houses thermal packaging product 100.

FIG. 7 depicts disclosed apparatus 1 in a semi-assembled state, ready for receiving a storable or perishable item.

FIG. 8 depicts the disclosed apparatus 1 in a semi-assembled state, preparing for closure.

FIG. 9 depicts the disclosed apparatus 1 in an assembled state, preparing for shipment.

FIG. 10 illustrates polystyrene core 50 encapsulated within a metallized polyethylene material 40.

FIG. 11 illustrates polystyrene core 50 which has been scored at an end thereof such that when it is encapsulated within a metallized polyethylene material 40, the thermal packaging product 100, 200 may bend or crack at a predetermined spot to minimize voids in packaging.

Before explaining the disclosed embodiments of the disclosed device in detail, it is to be understood that the device is not limited in its application to the details of the particular arrangements shown, since the device is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.

DESCRIPTION

Not every shipping container for perishables requires the same amount of insulation. With the disclosed device, the shipper may determine the thickness of insulation needed without the limitations of a pre-molded container that may provide either too little insulation or more than necessary.

Shippers are usually required to use a pre-molded container that may not actually fit their product. The disclosed device can be manufactured to a shipper's size requirement.

Pre-molded coolers typically can take up large amounts of space because of their rigid shape and structure. The disclosed device may be collapsed and stored flat until being folded into a usable expanded unit.

Pre-molded coolers are also expensive; often the cooler molds are thousands of dollars and require very expensive machines for use. The disclosed device requires no molds, eliminating most setup costs.

Pre molded coolers are efficient, however the disclosed device has been shown to be even more efficient. The test results from a company that manufactures molded coolers show, for example, that a 1.5″ embodiment of the disclosed device outperformed a 1.5″ pre-molded cooler by about twenty percent (20%).

The disclosed device utilizes polystyrene sheets encapsulated in a metallized polyethylene material, such as bubble/foil. Although bubble/foil was used because of its ability to reflect radiant heat, other suitable materials could be used to limit heat transfer through conduction.

The disclosed device is also easy to use. Scoring made in the polystyrene sheet before it is inserted into the metallized polyethylene material allows the polystyrene to crack at a predetermined spot to minimize voids in packaging.

Pre-molded coolers can be difficult to reuse. Because the disclosed device comprises a metallized polyethylene material on all sides, it will not absorb fluids. The thermal packaging products can easily be cleaned and disinfected for re-use.

Because molds must be larger than the coolers they produce, fabrication of pre-molded coolers is limited by the size of their molds. The disclosed device can be made into very large sizes, without requiring increasingly larger molds.

Pre-molded coolers may also crack in transit or at any time. Although the disclosed device could also crack, the polystyrene core is encapsulated completely and sealed in flexible metallized polyethylene material, such as bubble/foil, so the polystyrene would stay in place, continuing to insulate the perishable contents.

Various tests were conducted to determine the ability of the disclosed device to protect goods shipped under temperature-stressed conditions. The results of the tests are included herein to demonstrate the shipped goods were maintained within predetermined temperature ranges for prescribed durations.

The disclosed device provides for an insulated shipping container for transporting temperature-controlled materials. One having skill in the art will recognize that the device is capable of being used for any temperature-sensitive material for which temperature is to be controlled and can include cold, hot, and/or temperate items.

What is claimed is an insulated shipping container for temperature-sensitive transport, the container comprising an outer box or housing and a plurality of insulated inserts configured to be snugly and removably received in the outer box or housing. The plurality of insulated inserts are shaped to define a rectangular cavity of the outer box or housing, the cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps. Each of the plurality of insulated inserts comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides. The polystyrene core further comprising a scoring at ends thereof such that when it is encapsulated within a metallized polyethylene material to form a thermal packaging product, the thermal packaging product may bend or crack at a predetermined spot to minimize voids in packaging and to ensure a snug fit in the outer box or housing.

What is claimed is an insulated shipping insert for a temperature-sensitive transport container, the insulated insert comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides. The insulated insert is removably inserted into a rectangular cavity of an outer box or housing, the cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps. Each of the plurality of insulated inserts comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides. The polystyrene core further comprises a scoring at ends thereof such that when it is encapsulated within a metallized polyethylene material to form a thermal packaging product, the thermal packaging product may bend or crack at a predetermined spot to minimize voids in packaging and to ensure a snug fit in the outer box or housing.

What is claimed is a method of providing an insulated shipping container for temperature-sensitive transport, the method comprising the steps of: providing an outer box or housing, removably inserting a first insulated insert into a rectangular cavity of the outer box or housing, wherein a portion of the insulated insert forms a bottom wall, a first rectangular side wall and a top closure flap, removably inserting a second insulated insert into a rectangular cavity of the outer box or housing, wherein a portion of the second insulated insert forms a second, third and fourth rectangular side wall, thereby creating an insulated cavity. The method further comprises the step of inserting a transportable item. The method further comprises the closing of the top closure flap to house a transportable item. The method further comprises sealing the outer box or housing for shipment.

Although the disclosed device and method have been described with reference to disclosed embodiments, numerous modifications and variations can be made and still the result will come within the scope of the disclosure. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. 

I claim:
 1. An insulated shipping container for temperature-sensitive transport, the container comprising: an outer box or housing and a plurality of insulated inserts configured to be snugly and removably received in the outer box or housing; the plurality of insulated inserts being shaped to define a rectangular cavity of the outer box or housing, the cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps; each of the plurality of insulated inserts comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides; the polystyrene core further comprising a scoring at ends thereof to form a thermal packaging product when the core is encapsulated within a metallized polyethylene material; and wherein the thermal packaging product may bend or crack at a predetermined spot to minimize voids in packaging and to ensure a snug fit in the outer box or housing.
 2. An insulated shipping insert for a temperature-sensitive transport container, the insulated insert comprising: a polystyrene core encapsulated within a metallized polyethylene material on all sides; the insulated insert is removably inserted into a rectangular cavity of an outer box or housing, the cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps; each of the plurality of insulated inserts comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides; the polystyrene core further comprising a scoring at ends thereof to form a thermal packaging product when the core is encapsulated within a metallized polyethylene material; and wherein the thermal packaging product may bend or crack at a predetermined spot to minimize voids in packaging and to ensure a snug fit in the outer box or housing.
 3. A method of providing an insulated shipping container for temperature-sensitive transport, the method comprising the steps of: providing an outer box or housing; removably inserting a first insulated insert into a rectangular cavity of the outer box or housing, wherein a portion of the insulated insert forms a bottom wall, a first rectangular side wall and a top closure flap; and removably inserting a second insulated insert into a rectangular cavity of the outer box or housing, wherein a portion of the second insulated insert forms a second, third and fourth rectangular side wall, thereby creating all insulated cavity.
 4. The method of claim 3 further comprising the step of inserting a transportable
 5. The method of claim 3 further comprising the closing of the top closure flap to house a transportable item.
 6. The method of claim 5 further comprising sealing the outer box or housing for shipment. 